U.S. patent application number 17/473718 was filed with the patent office on 2022-03-03 for roofing products with zones of algae-resistant granules and method of manufacture.
The applicant listed for this patent is CertainTeed LLC. Invention is credited to Robert L. Jenkins, Shuang Liu, Mark W. Simon, Xiaofeng Tang.
Application Number | 20220064956 17/473718 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-03 |
United States Patent
Application |
20220064956 |
Kind Code |
A1 |
Tang; Xiaofeng ; et
al. |
March 3, 2022 |
ROOFING PRODUCTS WITH ZONES OF ALGAE-RESISTANT GRANULES AND METHOD
OF MANUFACTURE
Abstract
The present disclosure relates generally to roofing products,
for example, suitable for use covering and protecting the roofs of
structures. The present disclosure relates more particularly to a
roofing product including an upper section and an exposed section.
The roofing product includes a substrate having a top surface and a
bottom surface, and a plurality of zones of roofing granules
disposed on the top surface of the substrate. The plurality of
zones includes first, second and third zones within the exposed
section. The first zone includes a first collection of
algae-resistant roofing granules and has a first algae-resistance
intensity. The second zone includes a second collection of
algae-resistant roofing granules and has a second algae-resistance
intensity. The third zone has a third algae-resistance intensity
that is different from the first algae-resistance intensity.
Inventors: |
Tang; Xiaofeng; (Malvern,
PA) ; Liu; Shuang; (Malvern, PA) ; Jenkins;
Robert L.; (Honey Brook, PA) ; Simon; Mark W.;
(Phoenixville, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CertainTeed LLC |
Malvern |
PA |
US |
|
|
Appl. No.: |
17/473718 |
Filed: |
September 13, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16728173 |
Dec 27, 2019 |
11118354 |
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17473718 |
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62785532 |
Dec 27, 2018 |
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International
Class: |
E04D 13/00 20060101
E04D013/00; E04D 1/26 20060101 E04D001/26 |
Claims
1-20. (canceled)
21. A roofing product including an upper section and an exposed
section, the roofing product comprising: a substrate including a
top surface and a bottom surface; and a plurality of zones of
roofing granules disposed on the top surface of the substrate, the
plurality of zones including: a first zone within the exposed
section of the roofing product and comprising a first collection of
algae-resistant roofing granules, the first zone having a first
algae-resistance intensity; a second zone within the exposed
section of the roofing product and comprising a second collection
of algae-resistant roofing granules, the second zone having a
second algae-resistance intensity; and a third zone within the
exposed section of the roofing product and comprising a third
collection of algae-resistant roofing granules having a third
algaecide concentration, the third zone having a third
algae-resistance intensity; and wherein the first algae-resistance
intensity is different from the third algae-resistance intensity,
and wherein the second algae-resistance intensity is between the
first algae resistance intensity and the third algae-resistance
intensity.
22. The roofing product according to claim 21, further comprising:
a fourth zone within the exposed section of the roofing product and
comprising a fourth collection of algae-resistant roofing granules
having a fourth algaecide concentration, the fourth zone having a
fourth algae-resistance intensity.
23. The roofing product according to claim 21, wherein the fourth
algae-resistance intensity is different from the third
algae-resistance intensity.
24. The roofing product according to claim 21, wherein the first
collection of algae-resistant roofing granules has a first
algaecide concentration and the second collection of
algae-resistant roofing granules has a second algaecide
concentration, the first algaecide concentration being higher than
the second algaecide concentration.
25. The roofing product according to claim 21, wherein the first
collection of algae-resistant roofing granules has a first
algaecide concentration and the third collection of algae-resistant
roofing granules has a third algaecide concentration, the first
algaecide concentration being higher than the third algaecide
concentration.
26. The roofing product according to claim 25, wherein the first
algaecide concentration is in the range of 0.02% by weight to 20%
by weight and is higher than the third algaecide concentration.
27. The roofing product according to claim 24, wherein the first
algaecide concentration is in the range of 0.02% by weigh to 50% by
weight and is higher than the second algaecide concentration.
28. The roofing product according to claim 24, wherein the second
algaecide concentration is in the range of 0.02% by weight to 20%
by weight.
29. The roofing product according to claim 21, wherein the roofing
product is a roofing shingle, a roofing membrane, or a roofing
tile.
30. A method of manufacturing a roofing product according to claim
21, the method comprising: providing a substrate including a top
surface and a bottom surface; and depositing a plurality of zones
of roofing granules on the top surface of the substrate, the
plurality of zones including: a first zone within the exposed
section of the roofing product and comprising a first collection of
algae-resistant roofing granules, the first zone having a first
algae-resistance intensity; a second zone within the exposed
section of the roofing product and comprising a second collection
of algae-resistant roofing granules, the second zone having a
second algae-resistance intensity; a third zone within the exposed
section of the roofing product and comprising a third-collection of
algae-resistant roofing granules having a third algaecide
concentration, the third zone having a third algae-resistance
intensity wherein the first algae-resistance intensity is different
from the third algae-resistance intensity,
31. A roofing product including an upper section and an exposed
section, the roofing product comprising: a substrate including a
top surface and a bottom surface; and a plurality of zones of
roofing granules disposed on the top surface of the substrate, the
plurality of zones including: a first zone within the exposed
section of the roofing product and comprising a first group of
algae-resistant roofing granules that have a first algaecide
time-release characteristic, the first zone having a first
algae-resistant intensity; a second zone within the exposed section
of the roofing product and comprising a second group of
algae-resistant roofing granules that have a second algaecide
time-release characteristic, the second zone having a second-algae
resistant intensity; and a third zone within the exposed section of
the roofing product and comprising a third group of algae-resistant
roofing granules that have a third algaecide time-release
characteristic, the third zone having a third algae-resistant
intensity. wherein the first algaecide time-release characteristic
is different from the third algaecide time-release
characteristic.
32. The roofing product according to claim 31, wherein the first
algaecide time-release characteristic that is different from the
second algaecide time-release characteristic.
33. The roofing product according to claim 31, wherein the second
algaecide time-release characteristic that is different from the
third algaecide time-release characteristic.
34. The roofing product according to claim 31, wherein the first
algaecide time-release characteristic is faster than the third
algaecide time-release characteristic.
35. The roofing product according to claim 31, wherein the second
algaecide time-release characteristic is faster than the third
algaecide time-release characteristic.
36. The roofing product according to claim 31, wherein an average
algaecide release rate of the granules of the first zone is
different from an average algaecide release rate of the granules of
the third zone.
37. The roofing product according to claim 31, wherein an average
algaecide release delay of the granules of the first zone is
different from an average algaecide release delay of the granules
of the third zone.
38. The roofing product according to claim 31, wherein the first
algae-resistance intensity is different from the third
algae-resistance intensity, and wherein the second algae-resistance
intensity is between the first algae resistance intensity and the
third algae-resistance intensity.
39. The roofing product according to claim 31, further comprising:
a fourth zone within the exposed section of the roofing product and
comprising a fourth collection of algae-resistant roofing granules
having a fourth algaecide concentration, the fourth zone having a
fourth algae-resistance intensity, wherein the fourth
algae-resistance intensity is different from the third
algae-resistance intensity.
40. A method of manufacturing a roofing product according to claim
31, the method comprising: providing a substrate including a top
surface and a bottom surface; and depositing a plurality of zones
of roofing granules on the top surface of the substrate, the
plurality of zones including: a first zone within the exposed
section of the roofing product and comprising a first group of
algae-resistant roofing granules that have a first algaecide
time-release characteristic, the first zone having a first
algae-resistant intensity; a second zone within the exposed section
of the roofing product and comprising a second group of
algae-resistant roofing granules that have a second algaecide
time-release characteristic, the second zone having a second-algae
resistant intensity; and a third zone within the exposed section of
the roofing product and comprising a third group of algae-resistant
roofing granules that have a third algaecide time-release
characteristic, the third zone having a third algae-resistant
intensity. wherein the first algaecide time-release characteristic
is different from the third algaecide time-release characteristic.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/728,173, filed Dec. 27, 2019, which claims
the benefit of priority of U.S. Provisional Patent Application No.
62/785,532, filed Dec. 27, 2018, each which is hereby incorporated
herein by reference in its entirety.
BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure
[0002] The present disclosure relates generally to roofing
products, for example, shingles suitable for covering and
protecting the roofs of houses, buildings and other structures. The
present disclosure relates more particularly to roofing products
having algae-resistant granules.
2. Technical Background
[0003] Roofing shingles, such as asphalt shingles, frequently
include granules that provide color to the surface of the shingles
as well as other characteristics. Over time, particularly in warmer
humid climates, conventional shingles can develop dark blotches or
streaks that are aesthetically unpleasant. These blotches and
streaks are the result of the algae growth on the surface of the
roofing product.
[0004] In order to reduce or eliminate the blotching and streaking
caused by algae growth on the roofing products, they can be cleaned
using a cleaning solution that includes a strong oxidizer such as
bleach. However, maintaining shingles using such cleaning methods
requires frequent treatment, as the effective duration of the
cleaning is rather short. Algae growth can also be inhibited using
biocides, such as metals and inorganic metal oxides.
[0005] To combat such growth, many roofing products include
algae-resistant granules across the exposed surface of the shingle.
Such granules may, for example, have a layer including an
appropriate biocide, such as cuprous oxide and/or zinc oxide.
Although algae-resistant granules are effective at combating algae
growth, these granules are typically more expensive than standard
granules. Accordingly, simply further increasing the amount of
algae-resistant granules in order to inhibit algae growth in
environments that are very warm and humid can substantially
increase the cost of the roofing products.
[0006] The present inventors have determined that algae will spread
very quickly once its growth has initiated. Therefore, a roofing
shingle that is effective at inhibiting the initial formation of
algae growth, while limiting the use of expensive algae-resistant
granules, would be very attractive to builders and consumers.
SUMMARY OF THE DISCLOSURE
[0007] In one aspect, the present disclosure provides a roofing
product including an upper section and an exposed section, the
roofing product comprising: [0008] a substrate including a top
surface and a bottom surface; and [0009] a plurality of zones of
roofing granules disposed on the top surface of the substrate, the
plurality of zones including: [0010] a first zone within the
exposed section of the roofing product and comprising a first
collection of algae-resistant roofing granules, the first zone
having a first algae-resistance intensity; [0011] a second zone
within the exposed section of the roofing product and comprising a
second collection of algae-resistant roofing granules, the second
zone having a second algae-resistance intensity; and [0012] a third
zone within the exposed section of the roofing product and having a
third algae-resistance intensity, [0013] wherein the first
algae-resistance intensity is different from the third
algae-resistance intensity.
[0014] In another aspect, the disclosure provides a method of
manufacturing a roofing product according to the disclosure, the
method comprising: [0015] providing a substrate including a top
surface and a bottom surface; and [0016] depositing a plurality of
zones of roofing granules on the top surface of the substrate, the
plurality of zones including: [0017] a first zone within the
exposed section of the roofing product and comprising a first
collection of algae-resistant roofing granules, the first zone
having a first algae-resistance intensity; [0018] a second zone
within the exposed section of the roofing product and comprising a
second collection of algae-resistant roofing granules, the second
zone having a second algae-resistance intensity; and [0019] a third
zone within the exposed section of the roofing product and having a
third algae-resistance intensity, wherein the first
algae-resistance intensity is different from the third
algae-resistance intensity.
[0020] Additional aspects of the disclosure will be evident from
the disclosure herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings are included to provide a further
understanding of the methods and devices of the disclosure, and are
incorporated in and constitute a part of this specification. The
drawings are not necessarily to scale, and sizes of various
elements may be distorted for clarity. The drawings illustrate one
or more embodiment(s) of the disclosure, and together with the
description serve to explain the principles and operation of the
disclosure.
[0022] FIG. 1A is a schematic top view of a first portion of a
roofing product in accordance with an embodiment of the
disclosure;
[0023] FIG. 1B is a schematic top view of a second portion of a
roofing product that cooperates with the portion of FIG. 1A;
[0024] FIG. 1C is a schematic top view of a roofing product that
combines the portions of FIGS. 1A and 1B;
[0025] FIG. 2 is a schematic top view of another roofing product in
accordance with an embodiment of the disclosure;
[0026] FIG. 3 is a schematic top view of another roofing product in
accordance with an embodiment of the disclosure;
[0027] FIG. 4 is a schematic top view of yet another roofing
product in accordance with an embodiment of the disclosure;
[0028] FIG. 5 is a schematic top view of a roofing product with a
single substrate layer in accordance with an embodiment of the
disclosure;
[0029] FIG. 6 is a schematic top view of a roofing product in
accordance with an embodiment of the disclosure;
[0030] FIG. 7, is a schematic top view of another roofing product
in accordance with an embodiment of the disclosure;
[0031] FIG. 8 is a schematic top view of yet another roofing
product in accordance with an embodiment of the disclosure; and
[0032] FIG. 9 is a schematic top view of another roofing product in
accordance with an embodiment of the disclosure.
[0033] FIG. 10 provides a photograph of an example of algae growth
on a roofing shingle in outdoor conditions.
[0034] FIG. 11 provides a photograph of an example of algae growth
on a roofing shingle in an algae-growth chamber.
[0035] FIG. 12 provides photographs of comparative shingles and
shingles of the disclosure in which the shadowline zone of the shim
has 50% algae-resistant granules, after algae growth in an
algae-growth chamber.
DETAILED DESCRIPTION
[0036] As described above, the present inventors have determined
that algae will spread quickly once its growth has initiated, and
that a roofing product that is effective at inhibiting the initial
formation of algae growth would be very attractive to builders and
consumers.
[0037] Accordingly, one aspect of the disclosure is a roofing
product including an upper section and an exposed section. The
roofing product includes a substrate including a top surface and a
bottom surface, and a plurality of zones of roofing granules
disposed on the top surface of the substrate. The plurality of
zones includes a first zone within the exposed section of the
roofing product and comprises a first collection of algae-resistant
roofing granules, where the first zone has a first algae-resistance
intensity. The zones also include a second zone within the exposed
section of the roofing product and comprises a second collection of
algae-resistant roofing granules, where the second zone has a
second algae-resistance intensity. The zones also include a third
zone within the exposed section of the roofing product that has a
third algae-resistance intensity. The first algae-resistance
intensity is different from the third algae-resistance
intensity.
[0038] Such a roofing product is shown in FIGS. 1A to 1C. FIGS. 1A
and 1B show portions of a laminated structure that are combined in
FIG. 1C in a laminated roofing product 100 that has an exposed
section 102 and an upper section 104. The two portions include a
top layer 106 and a bottom layer 108 that together form a substrate
110 having a top surface 112 and a bottom surface 114. A plurality
of zones 120, 122, 124 of roofing granules are disposed on the top
surface 112 of the substrate 110. First zone 120 is disposed within
the exposed section 102 and contains a number of roofing granules
including a first collection of algae-resistant roofing granules,
which impart a first algae-resistance intensity to the first zone
120. Second zone 122 is also disposed within exposed section 102
and also contains a number of roofing granules including a second
collection of algae-resistant roofing granules, which imparts a
second algae-resistance intensity to the second zone. Likewise,
third zone 124 is also disposed within exposed section 102 and
contains roofing granules that include a third collection of
algae-resistant roofing granules that imparts a third
algae-resistance intensity to the third zone. While all three zones
120, 122 and 124 in roofing product 100 include both
algae-resistant roofing granules as well as conventional roofing
granules, the algae-resistance intensity of the third zone differs
from the first and second zones. The placement of these zones,
which have different algae-resistance intensities allows for the
controlled spatial distribution of antimicrobial elements to combat
algae and other growth in targeted locations.
[0039] In certain embodiments as otherwise described herein, the
roofing product is a roofing shingle, a roofing membrane, or a
roofing tile. For example, roofing product 100 is a laminated
asphalt roofing shingle. The substrate of roofing shingle 100 is
formed of top and bottom layers 106, 108 that are each formed of a
base sheet that is covered with a bituminous material to form an
asphalt shingle. The base sheet of each of layers 106, 108 is
formed of a fibrous mat that holds the bituminous material, for
example, base sheet is made of woven or non-woven glass fibers,
polymeric fibers, or a combination of glass and polymeric fibers.
In other embodiments, the base sheet is made of roofing felt that
holds the bituminous material. Further, the bituminous material an
adhesive surface that holds the granules on the roofing product. In
other embodiments, the substrate of the roofing product is made of
thermoplastic, thermoset polymer, metallic, cementitious, or other
materials as would be appreciated by those of ordinary skill in the
art.
[0040] The terms top and bottom, as used herein, refer to the
direction that is perpendicular to the angled underlying roof
structure, such that a stack of two layers on the roof includes a
bottom layer in contact with the underlying structure and a top
layer that covers the bottom layer. In contrast, the terms upper
and lower refer to the direction that is parallel to the roof
structure with regard to elevation, such that water runs down the
roof from an upper area of the roof to a lower area of the
roof.
[0041] The roofing granules disposed on the top surface of the
substrate of the roofing product described herein can have a range
of different material constructions, as will be appreciated by
those of ordinary skill in the art. In certain embodiments, as
otherwise described herein, the roofing granules include a base
particle having at least one coating layer disposed thereon. In
some embodiments, the base particles include chemically inert
materials, such as inert mineral particles, solid or hollow glass
or ceramic spheres, or foamed glass or ceramic particles. In
certain embodiments the base particles are inert mineral particles
that are produced by a series of quarrying, crushing, and screening
operations, and are generally intermediate between sand and gravel
in size (that is, between about #8 US mesh and #70 US mesh). In
some embodiments, the base particles have an average particle size
of from about 0.1 mm to about 5 mm, e.g., from about 0.2 mm to 2.5
mm, e.g., from about 0.4 mm to about 2.4 mm.
[0042] In certain embodiments as otherwise described herein, the
base particles include naturally occurring materials such as talc,
slag, granite, silica sand, greenstone, andesite, porphyry, marble,
syenite, rhyolite, diabase, greystone, quartz, slate, trap rock,
basalt, and marine shells, as well as recycled manufactured
materials such as crushed bricks, concrete, porcelain, fire clay,
and the like. Crushed slate particles can also be used to form
granules of a more or less flat morphology.
[0043] In certain embodiments the base particles are formed as
solid or hollow glass spheres in a similar range of sizes. In some
embodiments, the glass spheres are coated with a suitable coupling
agent to provide improved adhesion to a binder included in a
coating that surrounds the base particle.
[0044] As set forth above, at least some of the roofing granules
used on the roofing products described herein are algae-resistant
roofing granules. As described herein, algae-resistant roofing
granules include granules that comprise an inorganic and/or organic
algaecide disposed on the surface of or within the granule
structure.
[0045] In certain embodiments as otherwise described herein, at
least a portion of the algae-resistant granules include an
inorganic algaecide. For example, in some embodiments, the
inorganic algaecide is selected from the group consisting of copper
oxide, other copper compounds, zinc oxide, titanium dioxide,
silver, copper, zinc and mixtures thereof.
[0046] In certain embodiments as otherwise described herein, at
least a portion of the algae-resistant granules include an organic
algaecide. For example, in some embodiments, the organic algaecide
includes one or more of zinc pyrithione, amines and ammonium salts,
quaternary ammonium chloride,
4,5-dichloro-2-n-octyl-4-isothiazoline-3-one (DCOIT), tannin,
hexahydro-1,3,5-tris(2-hydroxyethyl)-s-triazine,
hexahydro-1,3,5-triethyl-s-triazine,
2-(tert-butylamino)-4-chloro-6-(ethylamino)-S-triazine,
tetrahydro-3,5-dimethyl-2H-1,3,5-thiadiazine-2-thione,
3-iodo-2-propyl butyl carbamate, sodium dimethyldithiocarbamate,
disodium ethylene bisdithiocarbamate, disodium
cyanodithioimidocarbamate, potassium N-methyldithiocarbamate,
potassium dimethyldithiocarbamate,
2,2-dibromo-3-nitrilopropionamide, 2,2-dibromo-2-nitroethanol,
2-bromo-2-nitro-1,3-propanediol,
2-methyl-2,3-dihydroisothiazol-3-one,
5-chloro-2-methyl-4-isothiazolin-3-one,
2-n-octyl-4-isothiazolin-3-one, chloroallyl-3,5,7-azoniaadamantane
chloride, tetrakishydroxymethyl phosphonium sulfate,
poly[oxyethylene(dimethyliminio)ethylene-(dimethyliminio)ethylene
dichloride], didecyl dimethyl ammonium chloride, and
dodecylguanidine hydrochloride.
[0047] In certain embodiments as otherwise described herein, the
third zone includes a third collection of algae-resistant roofing
granules. In other embodiments, the third zone is void of any
algae-resistant roofing granules. For example, in some embodiments,
the third zone does not include any roofing granules that comprise
an algaecide or other biocide.
[0048] The difference in algae-resistance intensity, as described
herein, includes any difference in the efficacy or manner in which
the algae-resistant granules prevent algae growth within the
vicinity of the corresponding zone of the roofing product. In some
embodiments, the difference in the algae-resistance intensity
includes a difference in the concentration of the algae-resistant
granules within the zones. The phrase `concentration of granules,`
as used herein, refers to the weight percentage of algae-resistant
granules to total granules per unit area. For example, two zones
can have different algae-resistance intensities by including the
same class of algae-resistant granules in each zone, but having
different concentrations of the algae-resistant granules per unit
area in each zone. In some embodiments, the difference in the
algae-resistance intensity includes a difference in the algaecide
concentration of the algae-resistant granules. The phrase
`algaecide concentration of algae-resistant granules` refers to the
weight percentage of algaecide in a certain class of
algae-resistant granules. For example, two zones can have different
algae-resistance intensities by including the same concentration of
algae-resistant granules in each of the zones, but including
algae-resistant granules in one zone that have a relatively high
concentration of algaecide and including algae-resistant granules
in the other zone that have a relatively low concentration of
algaecide. Thus, the zone with the algae-resistant granules that
have a higher concentration of algaecide may have a greater
algae-resistance efficacy or intensity, even if both zones have the
same number of algae-resistant granules. Further, in some
embodiments, the difference in algae-resistance intensity includes
a difference in algaecide time-release characteristics. For
example, in some embodiments, two zones can have different
algae-resistance intensities by respectively including
algae-resistant granules that have different algaecide release
rates. As another example, in some embodiments, two zones can have
different algae-resistance intensities by one of the zones
including algae-resistant granules that have an algaecide release
delay. Or the algae-resistant granules in different zones may have
different algaecide release delays. Further, the zones having
different algae-resistance intensities can have any combination of
the above differentiating characteristics.
[0049] More specifically, in certain embodiments as otherwise
described herein, the first zone has a first concentration of
algae-resistant roofing granules, the second zone has a second
concentration of algae resistant granules and the third zone has a
third concentration of algae-resistant roofing granules, and
wherein the first concentration is higher than the third
concentration. As set forth above, in some embodiments, the third
zone does not include any algae-resistant granules, and thus in
these embodiments the third concentration of algae-resistant
roofing granules is zero.
[0050] For example, in certain embodiments as otherwise described
herein, the first zone includes a concentration of algae-resistant
roofing granules in a range of 1% to 20%, e.g., in a range of 1% to
15%, e.g., in a range of 2% to 10%, e.g., in a range of 2% to 5%,
e.g., in a range of 2% to 3%, or in a range of 3% to 4% or in
arrange of 4% to 5%, or in a range of 5% to 10%, e.g., in a range
of 5% to 8%, e.g., in a range of 5% to 6%, or in a range of 6% to
7%, or in a range of 7% to 8%, or in a range of 8% to 10%, e.g., 8%
to 9% or 9% to 10%, or in a range of 10% to 15%, e.g., in a range
of 10% to 12%, or in a range of 12% to 15%, or greater than 15%, or
in a range of 15% to 20%, or greater than 20%, e.g., up to
100%.
[0051] Further, in certain embodiments as otherwise described
herein, the third zone includes a concentration of algae-resistant
roofing granules in a range of 0% to 15%, e.g., in a range of 1% to
10%, e.g., in a range of 1% to 5%, e.g., in a range of 1% to 2%, or
in a range of 2% to 3%, or in a range of 3% to 4% or in arrange of
4% to 5%, or in a range of 5% to 10%, e.g., in a range of 5% to 8%,
e.g., in a range of 5% to 6%, or in a range of 6% to 7%, or in a
range of 7% to 8%, or in a range of 8% to 10%, e.g., 8% to 9% or 9%
to 10%, or in a range of 10% to 15%, e.g., in a range of 10% to
12%, or in a range of 12% to 15%.
[0052] In certain embodiments as otherwise described herein, the
concentration of algae-resistant roofing granules in the first zone
is at least 1% higher than the concentration of algae-resistant
roofing granules in the third zone, e.g., at least 2%, at least 3%,
at least 5%, at least 7%, at least 9%, or at least 15% higher. In
certain embodiments the concentration of algae-resistant roofing
granules in the first zone is higher than the concentration of
algae-resistant roofing granules in the third zone by an amount in
a range of 1% to 12% higher, e.g., in a range of 1% to 3% higher,
or in a range of 3% to 5% higher, or in a range of 5% to 7% higher,
or in a range of 7% to 9% higher, or in a range of 9% to 12%
higher.
[0053] In certain embodiments as otherwise described herein, the
concentration of algae-resistant roofing granules in the second
zone is different from the concentration of algae-resistant
concentrations in the first zone and from the concentration of
algae-resistant roofing granules in the third zone. For example, in
some embodiments, the second concentration is between the first
concentration and the third concentration. In other embodiments,
the first and second concentrations of algae-resistant roofing
granules are the same.
[0054] For example, in some embodiments, the second zone includes a
concentration of algae-resistant roofing granules in a range of 1%
to 20%, e.g., in a range of 1% to 15%, e.g., in a range of 1% to
10%, e.g., in a range of 1% to 5%, e.g., in a range of 1% to 2%, or
in a range of 2% to 3%, or in a range of 3% to 4% or in arrange of
4% to 5%, or in a range of 5% to 10%, e.g., in a range of 5% to 8%,
e.g., in a range of 5% to 6%, or in a range of 6% to 7%, or in a
range of 7% to 8%, or in a range of 8% to 10%, e.g., 8% to 9% or 9%
to 10%, or in a range of 10% to 15%, e.g., in a range of 10% to
12%, or in a range of 12% to 15%, or in a range of 15% to 20%, or
greater than 20%, e.g., up to 100%.
[0055] In some embodiments, the concentration of algae-resistant
roofing granules in the second zone is at least 0.5% higher than
the concentration of algae-resistant roofing granules in the third
zone, e.g., at least 1%, at least 2%, at least 3%, at least 5%, at
least 7%, at least 9%, or at least 15% higher, or in a range of 1%
to 12% higher, e.g., in a range of 1% to 3% higher, or in a range
of 3% to 5% higher, or in a range of 5% to 7% higher, or in a range
of 7% to 9% higher, or in a range of 9% to 12% higher; and the
concentration of algae-resistant roofing granules in the first zone
is higher than the concentration of algae-resistant roofing
granules in the second zone, e.g., at least 0.5% higher, at least
1%, at least 2%, at least 3%, at least 5%, at least 7%, at least
9%, or at least 15% higher, e.g., in a range of 0.5% to 1% higher,
e.g., in a range of 1% to 12% higher, e.g., in a range of 1% to 3%
higher, or in a range of 3% to 5% higher, or in a range of 5% to 7%
higher.
[0056] In certain embodiments as otherwise described herein, the
first zone includes a first group of algae-resistant granules that
have a first algaecide concentration that is different from an
algaecide concentration of any of the granules of the third
zone.
[0057] For example, in some embodiments, the first zone includes
one class of algae-resistant granules, such that the entire first
collection of algae-resistant roofing granules has the first
algaecide concentration, while the third zone does not include any
algae-resistant granules. In other embodiments, each of the first
zone and the third zone includes a single class of algae-resistant
granules, but the two classes of granules are different and have
different algaecide concentrations. Still in other embodiments, the
first zone includes a mix of different classes of algae-resistant
granules, and at least one of the classes of granules, i.e., the
class that makes up the first group of algae-resistant granules in
the first zone, is not included in the third zone. In such a case,
the third zone may have none, one, or more than one class of
algae-resistant granules therein.
[0058] In certain embodiments as otherwise described herein, the
algae-resistant granules in the roofing product have algaecide
concentrations in a range from 0.02% by weight to 50% by weight,
e.g., in a range of 0.02% to 20%, e.g., in a range of 0.02% to 5%,
e.g., in a range of 0.02% to 2% by weight, e.g., in a range from
0.05% to 1.0%, e.g., from 0.05% to 0.5%, e.g., from 0.1% to
0.2%.
[0059] In certain embodiments as otherwise described herein, the
first group of algae-resistant granules have a first algaecide
concentration that is higher than any class of granules in the
third zone.
[0060] In certain embodiments as otherwise described herein, the
second zone includes a second group of algae-resistant granules
that have a second algaecide concentration that is different than
an algaecide concentration of any class of the granules in the
first zone or the third zone. In other embodiments, the first group
of algae-resistant granules has an algaecide concentration that is
the same as a class of algae-resistant granules in the second zone.
In other embodiments, the first algaecide concentration is higher
than the second algaecide concentration.
[0061] As set forth above, in certain embodiments as otherwise
described herein, the algae-resistant roofing granules include
classes of granules that have different algaecide time-release
characteristics. For example, in some embodiments, at least some of
the roofing granules include a class of algae-resistant granules
that have a barrier coating that substantially prevents algaecide
release from the algae-resistant granules for a predetermined
period. Likewise, in some embodiments, the granules include a class
of algae-resistant granules that release algaecide therefrom at a
different rate than at least one other class of algae-resistant
granules in the roofing product. Such classes of algae-resistant
granules that have different algaecide time-release characteristics
are described in U.S. Pat. No. 9,334,654, which is hereby
incorporated by reference herein in its entirety.
[0062] In particular, in certain embodiments as otherwise described
herein, the first zone includes a first group of algae-resistant
granules that have an algaecide time-release characteristic that is
different from an algaecide time-release characteristic of any of
the granules of the third zone. In other words, within the first
zone, there is at least one class of granules that has a certain
algaecide time-release characteristic and there are no granules in
the third zone that have that same time-release characteristic.
Thus, while the first and third zones may include some
algae-resistant granules that are in the same class, there is at
least one class of granules in the first zone that is not present
in the third zone. For example, in certain embodiments, the first
group of algae-resistant granules in the first zone have an
algaecide release rate that is different from the algaecide release
rate of any of the granules of the third zone. Likewise, in some
embodiments, the first group of algae-resistant granules in the
first zone have an algaecide release delay that is different from
an algaecide release delay of any of the granules of the third
zone.
[0063] In certain embodiments as otherwise described herein, the
first zone includes a first group of algae-resistant granules that
have an algaecide time-release characteristic that is different
from an algaecide time-release characteristic of any of the
granules of the second zone. For example, in some embodiments the
first zone includes a group of algae-resistant granules that have
an algaecide release delay that none of the granules in the third
zone have. Likewise, in some embodiments the first zone includes a
group of algae-resistant granules that have a faster time-release
of algaecide than the granules in the third zone. In other
embodiments, the first zone and second zone include the same class
or classes of algae-resistant granules, and have the same
time-release characteristics.
[0064] In certain embodiments as otherwise described herein, the
second zone includes a second group of algae-resistant granules
that have an algaecide time-release characteristic that is
different from an algaecide time-release characteristic of any of
the granules of the third zone. For example, in some embodiments
the second zone includes a group of algae-resistant granules that
have an algaecide release delay that none of the granules in the
third zone have. Likewise, in some embodiments the second zone
includes a group of algae-resistant granules that have a faster
time-release of algaecide than the granules in the third zone.
[0065] In certain embodiments as otherwise described herein, an
average algaecide release rate of the granules of the first zone is
different from an average algaecide release rate of the granules of
the third zone. Likewise, in certain embodiments, an average
algaecide release delay of the granules of the first zone is
different from an average algaecide release delay of the granules
of the third zone.
[0066] As will be understood by those of ordinary skill in the art,
the color of the granules may be imparted, for example, by coloring
pigments that are included in the granules, such as in a binder of
a coating on the base particle. Such pigments may include suitable
metal oxides.
[0067] Color, as expressed herein, may be measured using a color
space that is specified by a set of 1976 CIELAB (Commission
Internationale de L'Eclairage) color space coordinates of L*, a*,
and b*, wherein L* represents lightness of the color (L*=0 is
black, and L*=100 indicates diffuse white; specular white may be
higher), a* represents a position between red/magenta and green (a*
negative values indicate green while positive values indicate
magenta), and b* represents a position between yellow and blue (b*
negative values indicate blue and positive values indicate
yellow).
[0068] In certain embodiments as otherwise described herein, the
first collection of algae-resistant roofing granules has a
different color than the third collection of algae-resistant
roofing granules. For example, in some embodiments, the first
collection of algae-resistant roofing granules and third collection
of algae-resistant roofing granules have a color difference
.DELTA.E of at least 2, e.g., a .DELTA.E of at least 5, e.g., a
.DELTA.E of at least 10. In some embodiments, the first collection
of algae-resistant roofing granules and the second algae-resistant
roofing granules have a color difference .DELTA.E of at least 2,
e.g., a .DELTA.E of at least 5, e.g., a .DELTA.E of at least 10. In
other embodiments, the first collection of algae-resistant roofing
granules and the second algae-resistant roofing granules have a
similar color, or the same color. Further, in some embodiments, the
second collection of algae-resistant roofing granules and the third
algae-resistant roofing granules have a color difference .DELTA.E
of at least 2, e.g., a .DELTA.E of at least 5, e.g., a .DELTA.E of
at least 10.
[0069] In certain embodiments, one of the first, second, or third
zones provides a shadow formation that enhances the depth of three
dimensional features of the roofing product. To allow the
algae-resistant granules to blend with other granules within such a
shadow formation, in some embodiments the algae-resistant roofing
granules in one zone are darker than the granules in another zone.
For example, in certain embodiments, the first collection of
algae-resistant roofing granules and the third collection of
algae-resistant roofing granules differ from each other in color by
at least 2 L* CIE color units, e.g., at least 5 L* CIE color units,
e.g., at least 10 L* color units. Further, in certain embodiments
the first collection of algae-resistant roofing granules and the
second collection of algae-resistant roofing granules differ from
each other in color by at least 2 L* CIE color units, e.g., at
least 5 L* CIE color units, e.g., at least 10 L* color units.
Further still, in some embodiments, the second collection of
algae-resistant roofing granules and the third collection of
algae-resistant roofing granules differ from each other in color by
at least 2 L* CIE color units, e.g., at least 5 L* CIE color units,
e.g., at least 10 L* color units.
[0070] In certain embodiments as otherwise described herein, at
least some of the roofing granules of the roofing product include a
biocidal glass composition. Such biocidal glass compositions are
described in U.S. Pat. No. 9,408,383, which is hereby incorporated
by reference herein in its entirety. One aspect of roofing granules
including such a biocidal glass composition in the coating of the
granule, is that these roofing granules may be lighter in color
than other algae resistant roofing granules that include one or
more biocidal agents. Achieving a lighter-colored granule, such as
a buff or cream colored granule, allows for a broader color palette
for roofing products. In other embodiments, the roofing granules do
not include a biocidal glass composition.
[0071] The term zones, as used herein with regard to the roofing
granules, refer to areas of the top surface of the roofing product
substrate where the make-up of the roofing granules has one or more
unifying characteristic. In some cases, the zones may be contiguous
areas of the top surface, but the zones may also include several
non-contiguous areas, as described in examples below. On the other
hand, two adjacent zones will have some identifiable boundary. In
other words, two different zones cannot be both contiguous, have
the same composition and concentration of granules, and be disposed
on the same substrate layer, such that the boundary between the
zones is indiscernible. Instead, different zones may be disposed at
a distance from one another such that they are physically separated
by an intervening zone, or they may have different granule
compositions or mixtures, or they may be positioned on different
layers of the roofing product.
[0072] Specifically, in certain embodiments as otherwise described
herein, the first zone is disposed at a distance from the second
zone. For example, roofing product 100 shown in FIG. 1C, includes
first zone 120 and second zone 122. Each of the zones 120, 122
include the same class of algae-resistant roofing granules at the
same concentration, such that first zone 120 and second zone 122
have the same algae-resistance intensity. However, first zone 120
is disposed toward the upper end of exposed section 102, while
second zone 122 is disposed toward the lower end of exposed section
102 at the lower edge 126 of substrate 110. Accordingly, first zone
120 is separated from second zone 122, in particular with third
zone 124 positioned therebetween. Thus, the boundaries of first
zone 120 and second zone 122 can be identified by third zone 124,
which has a different concentration of algae-resistant granules
than either first zone 120 or second zone 122.
[0073] More specifically, first zone 120 is positioned in the
shadow line at the upper edge of exposed section 102 on the shim
formed by bottom layer 108. In particular, as shown in FIG. 1B,
first zone 120 is formed by segments of an elongate area 130 on the
shim 108 that is covered with the algae-resistant granules. The
segments that form the first zone, are those segments of area 130
that are exposed between the dragon teeth 140 formed on the upper
layer 106. Forming the first zone as an elongate area that is
partially covered can be beneficial for manufacturing the roofing
product, since the algae-resistant granules may be applied
uniformly across the entire width of the roofing product. In other
embodiments, segmented zones can be formed by algae-resistant
granules that are discretely applied in specific areas on the top
surface, without covering portions of the granules. Further, second
zone 122 of roofing product 100 is disposed at the lower edge of
the dragon teeth 140.
[0074] First and second zones 120 and 122 each have higher
concentrations of algae-resistant granules that third zone 124. The
position of the first and second zones in the shadow line on the
shim and at the bottom edge of the dragon teeth is beneficial in
addressing enhanced algae growth resulting from water pooling and
capillary effects. In particular, the increased concentration of
algae-resistant granules on the shim at the shadow line combats
algae growth heightened by moisture that gathers in the corners
between the dragon teeth and at the edge of the upper portion or
headlap. Likewise, the increased concentration of algae-resistant
granules on the lower edge of the dragon teeth combat algae growth
that is heighted by moister retention due to capillary effects at
the bottom edge of the hanging dragon teeth.
[0075] Although roofing product 100 has zones of different
algae-resistance intensity corresponding to differences in the
concentration of algae-resistant granules, other embodiments of the
roofing product have first, second, and third zones that are
positioned on the roofing product in the same layout as roofing
product 100, but have zones that differ in the algaecide
concentration within the algae-resistant roofing granules, rather
than the overall concentration of algae-resistant granules.
Likewise, in other embodiments that have zones in these same
locations, the zones have algae-resistant roofing granules with
different time-release characteristics.
[0076] In certain embodiments as otherwise described herein, the
second algae resistance intensity is different from the first algae
resistance intensity and from the third algae-resistance intensity.
An example of such a roofing product is shown in FIG. 2. Roofing
product 200 is a laminated roofing shingle including a substrate
210 formed by a top layer 206 disposed over and adhered to a bottom
layer 208. The top layer 206 includes an upper section 204 that
forms a headlap of the shingle and dragon teeth 240 that hang down
from the upper section 204 into an exposed section 202. The dragon
teeth 240 partially cover a shim 250 formed by bottom layer 208
that is visible between the dragon teeth 240.
[0077] The substrate 210 includes a top surface 212 that is covered
by a plurality of roofing granules organized into different zones.
Specifically, the roofing granules form a first zone 220 at the
upper edge of the exposed section 202 of the shingle in the shadow
line, a second zone 222 at the lower edge 226 of dragon teeth 240
and a third zone 224 that covers the remaining area of the exposed
section 202. The first zone 220 has a higher concentration of
algae-resistant roofing granules than the second zone 222.
[0078] In other embodiments that have the same zone positioning as
roofing product 200, the first zone includes granules with a higher
algaecide concentration than the granules of the second zone.
Still, in other embodiments with such zone positioning, the first
zone includes granules that have a faster algaecide release rate
than the granules of the second zone.
[0079] In certain embodiments as otherwise described herein, the
second algae-resistance intensity is different from the first
algae-resistance intensity and from the third algae-resistance
intensity. For example, in roofing product 200, first zone 220 has
a higher concentration of algae-resistant granules than second zone
222, which in turn has a higher concentration of algae-resistant
granules than third zone 224.
[0080] In certain embodiments as otherwise described herein, the
first zone is disposed at an upper edge of the exposed section of
the roofing product. For example, in roofing product 200, first
zone 220 is disposed between the dragon teeth 240 at the upper edge
of exposed section 202 at the shadow line.
[0081] In certain embodiments as otherwise described herein, the
first zone is disposed at an upper edge of the exposed section of
the roofing product and the second zone is disposed at a lower edge
of the exposed section of the roofing product. For example, in
roofing product 200, second zone is disposed at the lower edge 226
of the exposed section 202 at the bottom of the dragon teeth.
[0082] In certain embodiments as otherwise described herein, the
first zone is disposed at a lower edge of the exposed section of
the roofing product. Such an embodiment is shown in FIG. 3. Roofing
product 300 is a laminated roofing shingle including a substrate
310 formed by a top layer 306 disposed over and adhered to a bottom
layer 308. The top layer 306 includes an upper section 304 that
forms a headlap of the shingle and dragon teeth 340 that hang down
from the upper section 304 into an exposed section 302. The dragon
teeth 340 partially cover a shim 350 formed by bottom layer 308
that is visible between the dragon teeth 340.
[0083] The substrate 310 includes a top surface 312 that is covered
by a plurality of roofing granules organized into different zones.
Specifically, the roofing granules form a first zone 320 at the
lower edge of the exposed section 302 of the shingle at the lower
edge 326 of the dragon teeth, a second zone 322 at the upper edge
of exposed section 302 in the shadow line, and a third zone 324
that covers the remaining area of the exposed section 302. The
first zone 320 has a higher concentration of algae-resistant
roofing granules than the second zone 322.
[0084] In other embodiments that have the same zone positioning as
roofing product 300, the first zone includes granules with a higher
algaecide concentration than the granules of the second zone.
Still, in other embodiments with such zone positioning, the first
zone includes granules that have a faster algaecide release rate
than the granules of the second zone.
[0085] In certain embodiments as otherwise described herein, the
first zone is disposed at a lower edge of the exposed section of
the roofing product and the second zone is disposed at an upper
edge of the exposed section of the roofing product. For example, as
explained above, roofing product 300 has such a configuration.
[0086] In certain embodiments as otherwise described herein, the
first and second zones are disposed at a lower edge of the exposed
section of the roofing product. Such an embodiment is shown in FIG.
4. Roofing product 400 is a laminated roofing shingle including a
substrate 410 formed by a top layer 406 disposed over and adhered
to a bottom layer 408. The top layer 406 includes an upper section
404 that forms a headlap of the shingle and dragon teeth 440 that
hang down from the upper section 404 into an exposed section 402.
The dragon teeth 440 partially cover a shim 450 formed by bottom
layer 408 that is visible between the dragon teeth 440.
[0087] The substrate 410 includes a top surface 412 that is covered
by a plurality of roofing granules organized into different zones.
Specifically, the roofing granules form a first zone 420 at the
lower edge 436 of the exposed section 402 of the shingle at the
lower edge of the dragon teeth, a second zone 422 at the lower edge
436 of exposed section 402 at the lower edge of the shim, and a
third zone 424 that covers the remaining area of the exposed
section 402. The first zone 420 has a higher concentration of
algae-resistant roofing granules than the second zone 422. In other
embodiments, the first zone is disposed on the lower edge of the
shim and the second zone is disposed on the lower edge of the
dragon teeth.
[0088] In other embodiments that have the same zone positioning as
roofing product 400, the first zone includes granules with a higher
algaecide concentration than the granules of the second zone.
Still, in other embodiments with such zone positioning, the first
zone includes granules that have a faster algaecide release rate
than the granules of the second zone.
[0089] In certain embodiments as otherwise described herein, the
substrate has multiple layers, and wherein the first and second
zones are disposed on different layers of the substrate. For
example, roofing products 100, 200, 300 and 400 all include
substrates with multiple layers where the first zone and second
zone are on different layers. The terms "top layer" and "bottom
layer," as used herein, are only limited by their relationship to
one another, such that the top layer is above the bottom layer.
These terms are not limited with respect to any additional layers.
Accordingly, in some embodiments, the roofing product has
additional layers each of which may individually be above, below,
or between the top and bottom layers.
[0090] In other embodiments, the substrate has a single layer. For
example, roofing product 500, shown in FIG. 5, is a three-tab
shingle with a first zone 520, second zone 522 and third zone 524
disposed within an exposed section 502 on a top surface of the
single-layered substrate 510. The first and second zones 520, 522
both have a higher concentration of algae-resistant granules than
the third zone 524. Likewise, roofing product 600, shown in FIG. 6,
is a four-tab shingle with a first zone 620, a second zone 622, and
a third zone 624 disposed within an exposed section 602 on a top
surface of the substrate 610. The first and second zones 620, 622
both have a higher concentration of algae-resistant granules than
the third zone 624. Moreover, roofing product 700, shown in FIG. 7,
is a straight roofing product including a first zone 720, a second
zone 722, and a third zone 724 disposed within an exposed section
702 on a top surface of the substrate 710. First and second zones
720, 722 have a higher concentration of algae-resistant granules
than third zone 724.
[0091] In certain embodiments as otherwise described herein, the
first zone is disposed on a top layer of the substrate. In certain
embodiments, the second zone is disposed on a bottom layer of the
substrate. For example, in roofing product 300, first zone 320 is
disposed on the top layer 306 on the dragon teeth and second zone
322 is disposed on bottom layer 308 on the shim.
[0092] In certain embodiments as otherwise described herein, the
first zone is disposed on a bottom layer of the substrate. In
certain embodiments, the second zone is disposed on a top layer of
the substrate. For example, in roofing product 200, first zone 220
is disposed on the bottom layer 208 on the shim and second zone 222
is disposed on top layer 206 on the dragon teeth.
[0093] In certain embodiments as otherwise described herein, the
substrate of the roofing product includes at least one tab that
hangs downward from a body of the roofing product. For example,
roofing product 800, shown in FIG. 8, has a substrate 810 that
includes a body 842 and several tabs 840 that hang downward from
body 842. The substrate 810 includes several zones of roofing
granules in accordance with the disclosure, including a first zone
820 disposed in a shadow line adapted to be immediately lower than
a lower edge of an overlaid roofing product. Substrate 810 also
includes a second zone 822 disposed at the lower edge of the tabs
840. A third zone 824 is positioned between the first and second
zones 820, 822. Further, first and second zones 820, 822 have a
higher concentration of algae-resistant granules than third zone
824.
[0094] In certain embodiments as otherwise described herein, the
roofing product includes a fourth zone within the exposed section
that has an algae-resistance intensity that is different from that
of the third zone. For example, such a roofing product is shown in
FIG. 9. Roofing product 900 is a laminated roofing shingle
including a substrate 910 formed by a top layer 906 disposed over
and adhered to a bottom layer 908. The top layer 906 includes an
upper section 904 that forms a headlap of the shingle and dragon
teeth 940 that hang down from the upper section 904 into an exposed
section 902. The dragon teeth 940 partially cover a shim 950 formed
by bottom layer 908 that is visible between the dragon teeth
940.
[0095] The substrate 910 includes a top surface 912 that is covered
by a plurality of roofing granules organized into different zones.
Specifically, the roofing granules form a first zone 920 at the
upper edge of the exposed section on the shim, a second zone 922 at
the lower edge 936 of the exposed section 902 of the shingle at the
lower edge of the dragon teeth, a fourth zone 926 at the lower edge
936 of exposed section 902 at the lower edge of the shim, and a
third zone 924 that covers the remaining area of the exposed
section 902. The first, second and fourth zones have higher
concentrations of algae-resistant roofing granules than the third
zone 924.
[0096] In another aspect, the disclosure provides a method of
manufacturing a roofing product according to any of the embodiments
set forth above. The method includes providing a substrate
including a top surface and a bottom surface. A plurality of zones
of roofing granules are deposited on the top surface of the
substrate. The plurality of zones include a first zone within the
exposed section of the roofing product that includes a first
collection of algae-resistant roofing granules, where the first
zone has a first algae-resistance intensity. The plurality of zones
also includes a second zone within the exposed section of the
roofing product that includes a second collection of
algae-resistant roofing granules, where the second zone has a
second algae-resistance intensity. The plurality of zones also
includes a third zone within the exposed section of the roofing
product that has a third algae-resistance intensity, where the
first algae-resistance intensity is different from the third
algae-resistance intensity.
[0097] In certain embodiments as otherwise described herein,
depositing the plurality of zones of roofing granules includes
depositing the first collection of algae-resistant roofing granules
in the first zone and depositing additional roofing granules in the
first zone. The roofing granules can be deposited on the substrate
using a variety of different tools, as will be appreciated by those
of ordinary skill in the art. In some embodiments, the granules are
deposited on the substrate using an applicator. For example, in
some embodiments the applicator is configured to move over the top
surface of the substrate while opening and closing to apply roofing
granules to the substrate. In other embodiments the applicator is a
roller that includes apertures that hold and release granules on
the substrate as the applicator rolls over the top surface of the
substrate.
[0098] In certain embodiments as otherwise described herein, the
first collection of algae-resistant roofing granules is deposited
in the first zone before the additional roofing granules are
deposited in the first zone. For example, in some embodiments, the
algae-resistant roofing granules are deposited in specific
locations using an accurate applicator. The application of the
algae-resistant roofing granules is then followed by depositing
other roofing granules over the entire substrate surface to fill in
voids surrounding the algae-resistant roofing granules.
[0099] In certain embodiments as otherwise described herein,
providing the substrate includes applying a bituminous material to
a base sheet, and depositing the zones of roofing granules includes
depositing the granules on the bituminous material. For example, in
some embodiments the method includes applying a bituminous material
to a base sheet of roofing felt or a fiber mat. The roofing
granules are then deposited and adhere to the bituminous material
in order to produce an asphalt shingle with desirable
algae-resistance.
[0100] The products and methods of the disclosure are further
explained by the following non-limiting example:
EXAMPLE
[0101] FIG. 10 provides a photograph of an example of algae growth
on a roofing shingle in outdoor conditions. Less algae is observed
on the so-called "dragon teeth" 10, on which algae-resistant
copper-containing granules are applied, than on the shim 20, on
which no algae-resistant granules are applied. Moreover, more algae
is seen at the corner and edges of the shim, and on the shim along
the edge of the dragon teeth. The inventors surmise that this is
due to relatively more water being physically retained on the
shingle in these areas.
[0102] FIG. 11 provides a photograph of an example of algae growth
on a roofing shingle in an algae-growth chamber. Here, too, less
algae is observed on the so-called "dragon teeth" 10, on which
algae-resistant copper-containing granules are applied, than on the
shim 20, on which no algae-resistant granules are applied. And on
the shim, relatively more algae growth is observed along the shadow
line 21 and along the bottom edge 22.
[0103] FIG. 12 provides photographs of comparative shingles like
those in FIGS. 11 and 12 (i.e., no algae-resistant granules on the
shim) and shingles of the disclosure in which the shadowline zone
of the shim has 50% algae-resistant granules, after algae growth in
an algae-growth chamber. The shingles of the disclosure exhibited
much less algae growth on the shim, despite only having a portion
of the shim including algae-resistant granules.
[0104] Further aspects of the disclosure are provided by the
following non-limiting embodiments, which can be combined in any
number and in any fashion that is not technically or logically
inconsistent.
Embodiment 1. A roofing product including an upper section and an
exposed section, the roofing product comprising:
[0105] a substrate including a top surface and a bottom surface;
and
[0106] a plurality of zones of roofing granules disposed on the top
surface of the substrate, the plurality of zones including: [0107]
a first zone within the exposed section of the roofing product and
comprising a first collection of algae-resistant roofing granules,
the first zone having a first algae-resistance intensity; [0108] a
second zone within the exposed section of the roofing product and
comprising a second collection of algae-resistant roofing granules,
the second zone having a second algae-resistance intensity; and
[0109] a third zone within the exposed section of the roofing
product and having a third algae-resistance intensity,
[0110] wherein the first algae-resistance intensity is different
from the third algae-resistance intensity.
Embodiment 2. The roofing product according to embodiment 1,
wherein the roofing product is a roofing shingle, a roofing
membrane, or a roofing tile. Embodiment 3. The roofing product
according to embodiment 1 or embodiment 2, wherein the third zone
includes a third collection of algae resistant roofing granules.
Embodiment 4. The roofing product according to any of embodiments 1
to 3, wherein the first zone has a first concentration of
algae-resistant roofing granules, the second zone has a second
concentration of algae resistant granules and the third zone has a
third concentration of algae-resistant roofing granules, and
wherein the first concentration is higher than the third
concentration. Embodiment 5. The roofing product according to
embodiment 4, wherein the second concentration is different from
the first and third concentrations. Embodiment 6. The roofing
product according to any of embodiments 1 to 5, wherein the first
zone includes a concentration of algae-resistant roofing granules
in a range of 1% to 20%, e.g., in a range of 1% to 15%, e.g., in a
range of 2% to 10%, e.g., in a range of 2% to 5%, e.g., in a range
of 2% to 3%, or in a range of 3% to 4% or in arrange of 4% to 5%,
or in a range of 5% to 10%, e.g., in a range of 5% to 8%, e.g., in
a range of 5% to 6%, or in a range of 6% to 7%, or in a range of 7%
to 8%, or in a range of 8% to 10%, e.g., 8% to 9% or 9% to 10%, or
in a range of 10% to 15%, e.g., in a range of 10% to 12%, or in a
range of 12% to 15%, or in a range of 15% to 20%, or greater than
20%, e.g., up to 100%. Embodiment 7. The roofing product according
to any of embodiments 1 to 6, wherein the third zone includes a
concentration of algae-resistant roofing granules in a range of 0%
to 15%, e.g., in a range of 1% to 10%, e.g., in a range of 1% to
5%, e.g., in a range of 1% to 2%, or in a range of 2% to 3%, or in
a range of 3% to 4% or in arrange of 4% to 5%, or in a range of 5%
to 10%, e.g., in a range of 5% to 8%, e.g., in a range of 5% to 6%,
or in a range of 6% to 7%, or in a range of 7% to 8%, or in a range
of 8% to 10%, e.g., 8% to 9% or 9% to 10%, or in a range of 10% to
15%, e.g., in a range of 10% to 12%, or in a range of 12% to 15%.
Embodiment 8. The roofing product according to any of embodiments 1
to 7, wherein the concentration of algae-resistant roofing granules
in the first zone is at least 1% higher than the concentration of
algae-resistant roofing granules in the third zone, e.g., at least
2%, at least 3%, at least 5%, at least 7%, at least 9%, or at least
15% higher, or in a range of 1% to 12% higher, e.g., in a range of
1% to 3% higher, or in a range of 3% to 5% higher, or in a range of
5% to 7% higher, or in a range of 7% to 9% higher, or in a range of
9% to 12% higher. Embodiment 9. The roofing product according to
any of embodiments 1 to 8, wherein the second zone includes a
concentration of algae-resistant roofing granules in a range of 1%
to 20%, e.g., in a range of 1% to 15%, e.g., in a range of 1% to
10%, e.g., in a range of 1% to 5%, e.g., in a range of 1% to 2%, or
in a range of 2% to 3%, or in a range of 3% to 4% or in arrange of
4% to 5%, or in a range of 5% to 10%, e.g., in a range of 5% to 8%,
e.g., in a range of 5% to 6%, or in a range of 6% to 7%, or in a
range of 7% to 8%, or in a range of 8% to 10%, e.g., 8% to 9% or 9%
to 10%, or in a range of 10% to 15%, e.g., in a range of 10% to
12%, or in a range of 12% to 15%, or in a range of 15% to 20%, or
greater than 20%, e.g., up to 100%. Embodiment 10. The roofing
product according to any of embodiments 1 to 9, wherein the
concentration of algae-resistant roofing granules in the second
zone is at least 0.5% higher than the concentration of
algae-resistant roofing granules in the third zone, e.g., in a
range of 1% to 12% higher, e.g., in a range of 1% to 3% higher, or
in a range of 3% to 5% higher, or in a range of 5% to 7% higher, or
in a range of 7% to 9% higher, or in a range of 9% to 12% higher,
and the concentration of algae-resistant roofing granules in the
first zone is higher than the concentration of algae-resistant
roofing granules in the second zone, e.g., at least 0.5% higher,
e.g., in a range of 0.5% to 1% higher, e.g., in a range of 1% to
12% higher, e.g., in a range of 1% to 3% higher, or in a range of
3% to 5% higher, or in a range of 5% to 7% higher. Embodiment 11.
The roofing product according to any of embodiments 1 to 10,
wherein the first zone includes a first group of algae-resistant
granules that have a first algaecide concentration that is
different from an algaecide concentration of any of the granules of
the third zone. Embodiment 12. The roofing product according to any
of embodiments 1 to 11, wherein the algae-resistant granules in the
roofing product have algaecide concentrations in a range from 0.02%
by weight to 50% by weight, e.g., in a range of 0.02% to 20%, e.g.,
in a range of 0.02% to 5%, e.g., in a range of 0.02% to 2% by
weight, e.g., in a range from 0.05% to 1.0%, e.g., from 0.05% to
0.5%, e.g., from 0.1% to 0.2%. Embodiment 13. The roofing product
according to any of embodiments 1 to 12, wherein the first group of
algae-resistant granules have a first algaecide concentration that
is higher than any class of granules in the third zone. Embodiment
14. The roofing product according to any of embodiments 1 to 13,
wherein the second zone includes a second group of algae-resistant
granules that have a second algaecide concentration that is
different than an algaecide concentration of any class of the
granules in the first zone or the third zone. Embodiment 15. The
roofing product according to embodiment 14, wherein the first
algaecide concentration is higher than the second algaecide
concentration. Embodiment 16. The roofing product according to any
of embodiments 1 to 15, wherein the first zone includes a first
group of algae-resistant granules that have an algaecide
time-release characteristic that is different from an algaecide
time-release characteristic of any of the granules of the third
zone. Embodiment 17. The roofing product according to embodiment
16, wherein the first group of algae-resistant granules have an
algaecide release rate that is different from the algaecide release
rate of any of the granules of the third zone. Embodiment 18. The
roofing product according to embodiment 16 or embodiment 17,
wherein the first group of algae-resistant granules have an
algaecide release delay that is different from an algaecide release
delay of any of the granules of the third zone. Embodiment 19. The
roofing product according to any of embodiments 1 to 18, wherein
the first zone includes a first group of algae-resistant granules
that have an algaecide time-release characteristic that is
different from an algaecide time-release characteristic of any of
the granules of the second zone. Embodiment 20. The roofing product
according to any of embodiments 1 to 19, wherein the second zone
includes a second group of algae-resistant granules that have an
algaecide time-release characteristic that is different from an
algaecide time-release characteristic of any of the granules of the
third zone. Embodiment 21. The roofing product according to any of
embodiments 16 to 20, wherein an average algaecide release rate of
the granules of the first zone is different from an average
algaecide release rate of the granules of the third zone.
Embodiment 22. The roofing product according to any of embodiments
16 to 21, wherein an average algaecide release delay of the
granules of the first zone is different from an average algaecide
release delay of the granules of the third zone. Embodiment 23. The
roofing product according to any of embodiments 1 to 22, wherein a
color of the roofing granules in the first zone is different from a
color of the roofing granules in the third zone. Embodiment 24. The
roofing product according to any of embodiments 1 to 23, wherein
the first collection of algae-resistant roofing granules and third
collection of algae-resistant roofing granules have a color
difference .DELTA.E of at least 2, e.g., a .DELTA.E of at least 5,
e.g., a .DELTA.E of at least 10. Embodiment 25. The roofing product
according to any of embodiments 1 to 24, wherein the first
collection of algae-resistant roofing granules and the third
collection of algae-resistant roofing granules differ from each
other in color by at least 2 L* CIE color units, e.g., at least 5
L* CIE color units, e.g., at least 10 L* color units. Embodiment
26. The roofing product according to any of embodiments 1 to 25,
wherein the first zone is disposed at a distance from the second
zone. Embodiment 27. The roofing product according to any of
embodiments 1 to 26, wherein the second algae-resistance intensity
is different from the first algae-resistance intensity and from the
third algae-resistance intensity. Embodiment 28. The roofing
product according to any of embodiments 1 to 27, wherein the first
zone is disposed at an upper edge of the exposed section of the
roofing product. Embodiment 29. The roofing product according to
any of embodiments 1 to 28, wherein the first zone is disposed at a
lower edge of the exposed section of the roofing product.
Embodiment 30. The roofing product according to embodiment 28 or
embodiment 29, wherein the second zone is disposed at a lower edge
of the exposed section of the roofing product. Embodiment 31. The
roofing product according to embodiment 29 wherein the second zone
is disposed at an upper edge of the exposed section of the roofing
product. Embodiment 32. The roofing product according to any of
embodiments 1 to 31, wherein the substrate has multiple layers, and
wherein the first and second zones are disposed on different layers
of the substrate. Embodiment 33. The roofing product according to
embodiment 32, wherein the first zone is disposed on a bottom layer
of the substrate. Embodiment 34. The roofing product according to
embodiment 32 or embodiment 33, wherein the second zone is disposed
on a top layer of the substrate. Embodiment 35. The roofing product
according to embodiment 32, wherein the first zone is disposed on a
top layer of the substrate. Embodiment 36. The roofing product
according to embodiment 32 or embodiment 33, wherein the second
zone is disposed on a bottom layer of the substrate. Embodiment 37.
A method of manufacturing a roofing product according to any of
embodiments 1 to 36, the method comprising:
[0111] providing a substrate including a top surface and a bottom
surface; and
[0112] depositing a plurality of zones of roofing granules on the
top surface of the substrate, the plurality of zones including:
[0113] a first zone within the exposed section of the roofing
product and comprising a first collection of algae-resistant
roofing granules, the first zone having a first algae-resistance
intensity; [0114] a second zone within the exposed section of the
roofing product and comprising a second collection of
algae-resistant roofing granules, the second zone having a second
algae-resistance intensity; and [0115] a third zone within the
exposed section of the roofing product and having a third
algae-resistance intensity, wherein the first algae-resistance
intensity is different from the third algae-resistance intensity.
Embodiment 38. The method according to embodiment 37, wherein
depositing the plurality of zones of roofing granules includes
depositing the first collection of algae-resistant roofing granules
in the first zone and depositing additional roofing granules in the
first zone. Embodiment 39. The method according to embodiment 38,
wherein the first collection of algae-resistant roofing granules is
deposited in the first zone before the additional roofing granules
are deposited in the first zone. Embodiment 40. The method
according to any of embodiments 37 to 39, wherein providing the
substrate includes applying an bituminous material to a base sheet,
and wherein depositing the zones of roofing granules includes
depositing the granules on the bituminous material.
[0116] It will be apparent to those skilled in the art that various
modifications and variations can be made to the processes and
devices described here without departing from the scope of the
disclosure. Thus, it is intended that the present disclosure cover
such modifications and variations of this invention provided they
come within the scope of the appended claims and their
equivalents.
* * * * *